Elastic composite having dual elasticized regions, and a system and method for making the elastic composite

ABSTRACT

This elastic composite includes a base layer having a pair of side edges and a longitudinal centerline spaced inwardly from the side edges, and a first elastic construction supported by the base layer. The first elastic construction includes a first plurality of spaced apart elastic elements and a first top layer extending over the first elastic construction. The elastic composite also includes a second elastic construction supported by the base layer. The second elastic construction includes a second plurality of spaced apart elastic elements and a second top layer extending over the elastic construction. The first and second top layers are spaced apart and the first and second elastic constructions are spaced apart, so as to define a central non-elasticized region between the first and second elastic constructions.

This application claims the benefit of the filing date of U.S.Provisional Application Ser. No. 60/901,446, filed on Feb. 15, 2007. Theabove application is hereby incorporated by reference for all purposesand made a part of the present disclosure.

BACKGROUND OF THE INVENTION

The present invention relates generally to elastic composites. Moreparticularly, the present invention relates to an elastic composite thatcan be used in the manufacture of a garment, other textile or fabricstructures, similar material structures, and the like, but moreparticularly, disposable absorbent articles and garments. The elasticcomposite of the present invention is well suited in providing anelastic component that can be employed in one or more areas of thedisposable absorbent article. The present invention also relates to asystem and method of making the elastic. The elastic composite and thesystem and method for making the elastic composite are particularlysuited for use with or on disposable absorbent garments or articles suchas baby diapers and training pants. To illustrate various aspects of theinvention, exemplary and preferred embodiments are described herein inthe context of disposable absorbent garments.

U.S. Pat. Nos. 7,462,172 and 7,361,246 provide background information onelastic composites (and the manufacture of such composites) of the typerelevant to the present invention. Accordingly, some portions of thepublications have been included herein to facilitate description of theinvention. In any event, these two publications are also herebyincorporated by reference and made a part of the present disclosure, butonly to the extent that incorporated subject matter provides backgroundinformation and/or exemplary composites and processes suitable for useon, or with, the present inventive composites, systems, and methods.Thus, the incorporated subject matter shall not serve to limit the scopeof the present invention.

Disposable absorbent garments contemplated by the invention includedisposable diapers, disposable pull-on garments and training pants, andthe like. These garments are worn about the lower torso or waist of theuser so as to receive and contain urine and other bodily wastes. Thebenefits provided by the use of a disposable diaper on an infant arewell known and its use has become widespread. Disposable pull-ongarments include training pants, pull-on diapers, disposable underwear,and adult incontinence garments. As for training pants, these garmentsare used by young children to facilitate a child's transition from usingdiapers to wearing regular underpants (i.e., during toilet training).Training pants (and other disposable pull-on pants have closed sidessuch that the user or caregiver raises the garment about the user's legsto wear the garment and slips the garment downward about the user's legsto take it off.

The principal elements of a typical disposable absorbent garment includea liquid permeable inner layer (or topsheet), a liquid impermeable outerlayer (or backsheet), and an absorbent core sandwiched between the innerand outer layers. Elastic members may be incorporated into differentparts of the garment. For example, elastic members may be positionedlongitudinally along a diaper, generally outboard of the absorbent coreto effect a seal around the buttocks, legs, or both of the users. Inaddition, several elastic members (e.g., in the form of elongatedelastic threads or strands) may be positioned laterally throughout thewaist regions (including the side waist regions) of a disposableabsorbent garment. The resulting elastication allows the garment tostretch when it is put on and when it is worn. The elastication allowsthe garment to accommodate variations in waist size and leg size of theuser, while fitting snugly about the waist and legs.

When elastic members are incorporated into a part or area of thegarment, that part or area typically becomes a distinct, functionalcomponent of the garment. These elastic components include the sidepanels or ear portions, the waistband, and fastening tabs. The elasticcomponents to which the present invention is directed are generallyelongated, and may be a distinct portion of a larger, unitary piece, ora separate, attachable component. Furthermore, the elastic componenttypically contains one or more sections or layers in addition to theelastic members. In this regard, such an elastic component may bereferred to as an elastic composite of the type which the presentinvention is concerned.

Due in part to its multi-component construction, these elasticcomposites may require a dedicated sub-process for manufacture whichmust be accommodated by the greater garment manufacturing process.Alternatively, the elastic composite may be manufactured independentlyor simply, manufactured in a separate sub-process detached from thecentral garment manufacturing system. In either case, a source of theelastic composite may be provided as input to the garment manufacturingprocess.

In most applications, the elastic composite has a significant impact onthe fit and sealability of the garment, as well as the generalappearance and construction quality of the garment. The design andconstruction of the elastic composite can also represent a significantportion of the cost of manufacturing the garment. It is, therefore,always desirable to provide a functionally and/or aesthetically improvedelastic composite or a cost effective system and method of making theelastic composite.

It is contemplated that, in some applications, manufacturing elasticcomposite having dual elasticized regions may prove more efficient andeconomical than producing elastic composites having a single elasticizedregion (even when single elasticized elastic composites are ultimatelyemployed). In one respect, the present invention addresses theparticular technical challenge of providing dual (or multiple)elasticized regions on ari elastic composite. In another respect, theinvention addresses the technical challenge of providing a system andmethod that is practical, efficient, and cost effective. For example,the system and method should preferably utilize commonly availablecomponents and sub-processes.

In any event, it is desirable for the target elastic composite (havingdual elasticized regions), system, and method of manufacturing to bepractical, and provide functional or aesthetic attributes. It is alsodesirable that the design and construction of the elastic composite hasa minimal, if not positive, impact on the efficiency of present systemsand methods. The design and construction should also have a minimal, ifnot positive, impact on the overall manufacturing cost of the elasticcomposite or the final product.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an elastic composite is providedfor use in manufacturing disposable absorbent garments. The elasticcomposite includes a base layer having a pair of side edges and alongitudinal centerline spaced inwardly from the side edges, and a firstelastic construction supported by the base layer. The first elasticconstruction includes a first plurality of spaced apart elastic elementsand a first top layer extending over the first elastic construction. Theelastic composite also includes a second elastic construction supportedby the base layer. The second elastic construction includes a secondplurality of spaced apart elastic elements and a second top layerextending over the elastic construction. The first and second top layersare spaced apart and the first and second elastic constructions arespaced apart, so as to define a central non-elasticized region betweenthe first and second elastic constructions. Preferably, the firstelastic construction and the second elastic construction are spacedinwardly from the first side edge and the second side edge,respectively. More preferably, the first and second elasticconstructions are spaced inwardly from the first and second side edges,respectively, to define first and second non-elasticized regionstherebetween. In a preferred embodiment, the central non-elasticizedregion is a single layer, seamless construction. In further embodiments,the plurality of spaced apart elastic elements are disposed in generallyparallel relation and/or distributed in a direction generally parallelwith the longitudinal centerline, and/or applied in the cross-machinedirection.

In another aspect of the present invention, a method is provided formaking an elastic composite having dual elasticized regions. The methodentails conveying a base web and integrating a first elasticsub-composite with the base web. Then, a second elastic sub-composite isintegrated with the base web, whereby the second elastic sub-compositeis spaced apart from the first elastic sub-composite. As a result, anelastic composite having dual elasticized regions is produced. Infurther embodiments, the method may include one or more additional stepsinvolving the integration of yet another (e.g., a third) elasticsub-composite with the base web (already having dual elasticizedregions). The resulting product is another elastic composite withmultiple elasticized regions.

In another aspect of the present invention, a method of making anelastic composite (having dual elasticized regions) entails conveying afirst web and applying elastic elements to the first web to produce afirst elastic sub-composite. A base web is then conveyed and the firstelastic sub-composite is integrated with the base web. A second web isconveyed and elastic elements are applied to the second web to produce asecond elastic sub-composite. The second elastic sub-composite is thenintegrated with the base web, thereby producing an elastic compositehaving dual elasticized regions. In one embodiment, the steps ofapplying elastic elements are performed simultaneously such that theelastic elements are applied simultaneously about the first and secondwebs to produce two webs of first and second elastic sub-composites.

In yet another aspect of the present invention, an elastic composite isprovided for use in manufacturing disposable absorbent garments. Theinventive elastic composite includes a base layer and a first elasticsub-composite supported by the base layer. The first elasticsub-composite has a first plurality of spaced apart elastic elementsdisposed in generally parallel relation, and a top layer extending overthe first plurality of elastic elements. The inventive elastic compositefurther includes a second elastic sub-composite supported by the baselayer, the second elastic sub-composite having a second plurality ofspaced apart elastic elements disposed in generally parallel relationand a top layer extending over the second plurality of elastic elements.Moreover, the first and second sub-composites are spaced apart to definea central non-elasticized region (“dead zone”) therebetween. Preferably,the first and second sub-composites are spaced apart to define aseamless central non-elasticized region formed by the base layer. Morepreferably, the base layer includes a first side edge and a second sideedge, and the first plurality of elastic elements are spaced inwardlyfrom the first side edge to form (in addition to the centralnon-elasticized region) a first non-elasticized region therebetween, andthe second plurality of elastic elements are spaced inwardly from thesecond side edge to form a second non-elasticized region therebetween.

For purposes of the present description, the term “elastic band” or“elastic composite” refers to a multi-layer construction. In thisconstruction, a plurality of elastic members, such as threads orstrands, are disposed adjacent one or more layers, e.g., backsheet andtopsheet. In this way, the elastic elements impart elasticity to theadjacent layers and thus, to that part of the garment or other textilestructure. Such an elastic structure may be a distinct attachablecomponent of the garment or textile structure or may be a distinctportion or section of the garment body or textile structure or a larger,unitary component of the garment body or textile structure. As usedherein, the term “elastic sub-composite” shall mean a multi-componentconstruction combination that includes elastic elements integrated witha substrate layer. Further, an elastic sub-composite provides onecomponent that may be integrated with other components to form theelastic composite and impart elastic properties thereto.

As used herein, the term elastic composite having multiple, or aplurality of, elasticized regions includes those having dual elasticizedregions. Moreover, all elastic composites having multiple or, aplurality of elasticized regions, are defined as having at least dualelasticized regions. For example, any elastic composite having threeelasticized regions will have dual elasticized regions, as long as twoelasticized regions are supported and spaced apart on a substrate orbase layer, and at some point in the manufacturing process, consists ofthe only pair of elasticized regions on the base layer or base web.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a disposable absorbent garment in the unfoldedconfiguration;

FIG. 2A is a plan view of an elastic composite;

FIG. 2B is a plan view of the elastic composite of FIG. 2A shown in anextended, stretchable condition;

FIG. 3 is a perspective view of the elastic composite of FIG. 2A with acut-out to show an elastic construction;

FIG. 4 is a plan view of another disposable absorbent garment;

FIG. 5 is a plan view of an elastic composite having dual elasticizedregions, according to the prior art;

FIG. 6 is a simplified schematic of a system for manufacturing anelastic composite having a dual elasticized region, according to theprior art;

FIG. 7 is a top view of an elastic element applicator assembly for usewith the system of FIG. 6;

FIG. 8 is a side view of the assembly of FIG. 7;

FIG. 9 is a simplified process illustration of making the elasticcomposite, according to the prior art;

FIG. 10 is a detail view of a conveyor assembly for the system of FIG.6;

FIG. 11A is a perspective view of an elastic composite having dualelasticized regions;

FIG. 11B is a perspective view of another elastic composite having dualelasticized regions;

FIG. 11C is a perspective view of yet another elastic composite havingdual elasticized regions;

FIG. 12 is a simplified perspective view, including a cutout, of anelastic composite having dual elasticized regions, according to thepresent invention;

FIG. 12A is an exploded view of the elastic composite in FIG. 12;

FIG. 12B is a lateral cross-sectional view of the elastic composite inFIG. 12, across line 12B-12B;

FIG. 12C is a longitudinal cross-sectional view of the elastic compositein FIG. 12, across line 12C-12C;

FIG. 13 is a simplified perspective view of an elastic compositeaccording to an alternative embodiment of the present invention;

FIG. 13A is a lateral cross-sectional view of the elastic composite inFIG. 13;

FIG. 14 is a simplified illustration of a roll or reel supporting a webof the elastic composite in FIG. 12;

FIG. 14A is a perspective view of a roll or reel supporting a web of theelastic composite in FIG. 12, with hook material being applied thereto;

FIG. 15 is a lateral cross-sectional view of an elastic composite havinga hook material applied thereon, according to the present invention;

FIG. 15A is a lateral cross-sectional view of an elastic compositehaving a hook material applied thereon, according to the prior art;

FIG. 16 is a simplified flow chart illustrating basic steps or stages ofa method of making an elastic composite having dual elasticized regions,according to the present invention;

FIG. 17 is a simplified flow chart illustrating a variation of a methodof making an elastic composite having dual elasticized regions,according to the present invention;

FIG. 18 is a simplified flow chart illustrating an exemplary method ofmaking an elastic composite having dual elasticized regions, accordingto the present invention;

FIG. 19 is a simplified schematic of a system for manufacturing theelastic composite, according to the present invention;

FIG. 20 is a simplified process illustration of a portion of the systemin FIG. 19; and

FIG. 21 is a simplified schematic of an alternative system formanufacturing the elastic composite, according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Generally, the present invention relates to an elastic composite, and asystem and method for making the elastic composite. More particularly,the invention is directed to an elastic composite having a pair ofelasticized regions that are mutually spaced apart and physicallyseparated. Such a pair of elastic constructions on an elastic compositemay be referred to herein as “dual elasticized regions.”

As described previously, various aspects of the present invention areparticularly suited to or for a disposable absorbent garment, such asbaby diapers and training pants. To illustrate the invention andpreferred embodiments of the invention, much of the following DetailDescription will be provided in the context of such disposable absorbentgarments. It is contemplated that various aspects of the inventivecomposite, garment, system, and process may be applicable to othermaterial structures and processes. This Detailed Description andexemplary embodiment should not, therefore, be construed as limiting theinvention to the structures, configurations, methods, and processesdescribed herein.

FIGS. 1-11 are provided for background and to illustrate structures andprocesses potentially relevant to the present invention. Some Figures,and accompanying description, are provided to illustrate the prior artand for the purpose of highlighting the contributions to the prior artprovided by the present invention. The same Figures also illustrate useof the elastic composite, system, or method of the invention, and/or aproduct derived from the inventive elastic composite. In particular,each of FIGS. 1 and 4 depicts a garment that incorporates an elasticcomposite structure or elastic composite as described and disclosed inthe prior art. The elastic composite (having a single elasticizedregion) shown may, however, be provided by, or derived from, the elasticcomposite (having dual elasticized regions) of the present invention.

In FIGS. 1 and 4, a disposable absorbent garment is shown that issuitable for the invention and in the form of a diaper having one ormore elastic composites incorporated therein. FIGS. 6-10 illustrate asystem, system components, and a process of making the elastic compositehaving a single elasticized region as previously described and disclosedin the prior art. See U.S. Pat. Nos. 7,462,172 and 7,361,246. TheseFigures and accompanying descriptions of the prior art are provided tofacilitate description of the present inventive elastic composite andhighlight the differences and improvements provided by the presentinventive system and method.

The described prior art systems and processes are particularly focusedon the application or integration of the elastic elements upon or withone of the layers of the composite. In one aspect of the presentinvention, the invention is also focused on the application orintegration of such elastic elements. In a further aspect of the presentinvention, the invention provides a process of integrating elastic sub-or pre-composite structures onto a base element such as a base non-wovenweb to generate an elastic composite having dual and independentelasticized regions.

The disposable absorbent garment 110 in FIG. 1 is of a type that can beplaced against or in proximity to the body of a wearer so as to absorband to contain various bodily exudates. It should be noted, however,that the present invention is applicable to a variety of disposableabsorbent articles and garments, including training pants and a varietyof adult incontinence products. As will be described below, theinventive elastic composite or elastic composite band may provide a sidepanel or ear portion, a waistband, a fastening tab or band, or otherdistinct elastic component of the garment or article. The inventiveelastic composite may also be incorporated into an ear portion toelasticate the ear portion or to supplement the ear portion with anelasticated fastening tab.

FIG. 1 is introduced to illustrate some basic features of a disposablediaper 110. The diaper 110 includes three main regions aligned along animaginary longitudinal axis or plane AA. These regions include a firstwaist region 112 (typically at the front of the user when the garment110 is worn), a back waist region 114, and a crotch region 116. Thediaper 110 is also characterized by a front edge 140, a backlongitudinal edge 142, a first lateral or side edge or side margin 144,and a second lateral or side edge or side margin 146.

Along a lateral direction, the diaper 110 includes ear regions or earportions 118 extending laterally from the waist regions 112, 114.Together, the waist regions 112, 114 and crotch region 116 may bereferred to as forming a central body portion 120 of the garment 110that is positioned within side edges 144, 146. The body portion 120 mayalso be referred to as being formed by a liquid permeable inner layer ortopsheet 152, a liquid impermeable outer layer or backsheet (not shown),and an absorbent core 154 sandwiched between the two layers. The earportions 118 further include fastening tabs 124 for attaching the waistregions 112, 114 together. The diaper 110 also has an elastic waistband130 positioned generally along the back edge 142 to facilitate fasteningand to enhance the fit and seal of the diaper 110. When the hourglassshaped diaper 110 is worn, the crotch region 116 fits about the crotchof the wearer, and the front and back waist regions, 112 and 114, fitabout the corresponding waist areas. The ear portions 118, on the otherhand, wrap about the wearer and the fastening tabs 124 engage to form acomplete, all-around waistline of the diaper 110.

FIG. 2A depicts a typical elastic composite band 210, now generallyknown in the art, but which may also be derived from the elasticcomposite of the present invention. The elastic composite band 210 isone particularly suited for use as a side panel or fastening tab of adisposable absorbent garment (see, e.g., FIG. 1). FIG. 3 provides aperspective view and partial cutout of the elastic composite band 210.The elastic composite band 210 may be characterized by an imaginarycenterline LL. The centerline LL preferably corresponds with the machinedirection of the elastic composite band 210 during manufacture. Theelastic band 210 also has side or longitudinally extending side edges210 a and 210 b and laterally extending end edges 210 c and 210 d. InFIG. 1, the elastic composite band 210 is shown in the stretched stateas, for example, when a garment incorporating the elastic composite band210 is worn. In this state, the elastic composite band 210 stretches, inthe lateral or cross-machine direction (denoted by arrows XX).

As used herein, the term “machine” direction refers to the direction atwhich the component, or more particularly, the material web from whichthe elastic composite is derived (e.g., cut from) is driven in anassembly line during manufacturing. The term “cross-machine direction”or “cross-directional,” on the other hand, refers to the direction thatis perpendicular to the machine direction. With reference to the elasticcomposite 210 of FIG. 2, the cross machine direction is the direction XXextending laterally or perpendicularly relative to the longitudinal lineLL.

The elastic composite band 210 has a central region 214 in which anelastic construction is situated. Extending laterally from this centralelastic or elasticized region 214 are regions 216 and 218, which aresubstantially non-elasticized (“dead zones”). As shown in FIG. 2A, theregions 216, 218 occupy the expanse between the central elastic region214 and the side edges 210 a, 210 b. Now with reference to FIG. 3, theelastic composite band 210 has a top layer 318 and a bottom or baselayer 320. The two layers 318, 320 preferably extend the total width andlength of the elastic composite band 210, thereby providing the sideedges 210 a, 210 b, and the end edges 210 c, 210 d. Both the base layer320 and the top layer 318 are preferably a non-woven, breathable,disposable material such as propylene, non-woven fabric, breathablepolyethylene/polypropylene films, or non-porous films (or combinationsof these materials). The base layer 320 and top layer 318 adhere to oneanother, thereby sandwiching and securing a plurality of elastic strands322 therebetween.

The elastic strands 322 may be substituted by suitable elastic elementssuch as elastic strands, threads, ribbons, and elastic glue beads. Theelastic elements or strands 322 are distributed along a direction thatextends between the side edges 210 a, 210 b and generally parallel with(or corresponding to) centerline LL. Further, each elastic element 322is generally aligned or oriented in a direction corresponding with thelateral or cross-machine direction, i.e., in a direction generallyperpendicular to the longitudinal center line LL and intersecting theside edges 210 a, 210 b. Preferably, the elastic elements 322 aredisposed in generally parallel relation and spaced apart generallyequally along the longitudinal direction. More preferably, the elasticelements 322 are of generally equal length. Accordingly, when theelastic composite band 210 is worn, the elastic elements 322 impartelasticity to the structure which allows the band 210 to stretch in thelateral or cross-machine direction XX. Because the elastic elements 322are independent, spaced apart and maintained along the generally lateraldirection, the stretch and contraction of the elasticized material aregenerally in the lateral direction as well. This alternative may befunctionally and aesthetically advantageous in some garmentapplications.

The elastic elements 322 are preferably tensioned during securementbetween the top and base layers 318, 320. FIG. 2B illustrates theelastic composite band 210 in a laterally stretched condition. In thiscondition, the central elastic region 214 has a width that is almostequal to the non-elasticized zones 216 and 218. When returned to thenon-laterally stretched or relaxed condition, as shown in FIG. 2A, thecentral elastic region 214 contracts and crimps to a substantiallyreduced width. In this condition or state, the contracted elasticelements 322 shirrs the elastic composite 210 and provide pleats 234 inthe contracted elastic region 214.

In one application of the present invention, a reel or roll of a web ofan elastic composite having dual elasticized regions is provided. Theelastic composite is typically cut along the longitudinal centerline toproduce two separate elastic composites. Such a reel or roll may bereadily integrated into, and/or provide as input to a system and processfor manufacturing a disposable absorbent garment. In one aspect, such areel or roll is an output of a method of making an elastic compositeaccording to the present invention.

Returning to FIG. 1, the disposable absorbent garment 110 employs one ormore elastic composite bands, as described above. The disposableabsorbent garment 110 employs in each of the ear portions 118, afastening tab 124 having an elastic composite construction. As thefastening tab 124, the elastic composite band is configured such thatone non-elasticized region 124 a is attached to and overlaps the centralbody 120 of the garment 110 while a second non-elasticized region 124 bis situated outboard of the side margins 144, 146. An elasticized region124 c, as shown in FIG. 1, provides elasticity, and thus, stretch in thelateral or cross-machine direction (of the elastic composite). Inrespect to the rest of the garment 110, the elasticity or stretchprovided by the central elastic region 124 c directed along a directionthat is generally perpendicular to the longitudinal center line AA ofthe garment 110, and corresponds with a direction that wraps about thewaistline of the user.

The disposable absorbent garment 110 in FIG. 1 also provides an elasticcomposite, as the waistband 130. The waistband 130 is situated centrallyin the waist region 114. Further, the elastic composite waistband 130 isdisposed such that non-elasticized regions 130 a, 130 b are positionedoutwardly of the longitudinal line AA of the garment 110, while anelasticized region 130 c is positioned centrally across the longitudinalcenter line AA. Moreover, the elasticized region 130 c is configuredsuch that the elastic strands are aligned or oriented in a directionthat is generally perpendicular to the longitudinal centerline AA. Inthis way, the elastic composite waistband 130 imparts elasticity aboutthe waist region 114 of the garment 110, and in a directioncorresponding with the direction of waistline about the user.

FIG. 4 depicts an alternative disposable absorbent garment 410.Specifically, FIG. 4 depicts a disposable absorbent garment 410employing elastic composites as attachable ear portions or side panels414. The elastic composite side panels 414 are separate components thatare attached to a central body 420 of the garment 410. The elasticcomposite side panels (or ear portions) 414 are attached near one waistedge 442 of the garment 410 and such that the centerline AA of the sidepanel 414 is generally parallel with the longitudinal centerline AA ofthe garment 410. Moreover, each of the elastic composite side panels 414has a non-elasticized region 414 a that is positioned outboard of theside margins 446 of the garment 410 and a second non-elasticized region414 b that is attached inboard of the side margin 446 (or side margin444).

FIG. 5 depicts an elastic composite 710 of the prior art that isdifferent from the previously described elastic composite band (see e.g.FIG. 2) in that the elastic composite band 710 includes two elasticizedregions 714 a and 714 b. The elasticized region 714 a, 714 b arepreferably equidistantly spaced apart on either side of the longitudinalcenterline AA. The spacing of the elasticized regions 714 a, 714 bcreates right and left non-elasticized or dead regions 716, 718, as wellas central non-elasticized region 750. The elasticized regions 714 a,714 b imparts elasticity to elastic composite band 710 a in the lateraldirections XX, and in the central non-elasticized region 750, also inthe opposite lateral direction VV. The elastic composite 710 may beemployed as a dual elasticized component, or may be cut along thelongitudinal centerline AA to produce two separate elastic compositeseach with a single elasticized region. Such elastic composite(s) maythen be employed, for example, as any one of the elastic composites 124,130, 410 in FIGS. 1 and 4. In one aspect of the present invention, anelastic composite having dual elasticized regions is provided as adirect improvement over the prior art elastic composite 710 shown inFIG. 5.

Before describing the elastic composite of the invention, FIGS. 6-10 areprovided to illustrate a known system, and system components, andprocess of making or manufacturing an elastic composite, as previouslypracticed and described in more detail in U.S. Patent application Ser.Nos. 10/733,649 and 11/021,424. In the prior art process illustratedtherein, two elastic composite web outputs 1031 are produced from fourseparate non-woven web inputs 1003 a, 1003 b, 1003 c, and 1003 d.

Referring first to FIG. 6, a system 1001 includes four separatenon-woven web inputs 1003 a-1003 d, which provide a web or roll ofnon-woven material for the elastic composite. The system furtherincludes an output assembly or reel 1005 that receives two elasticcomposite webs 1031 from the rest of the process. These two separateelastic webs may be later fixed together after manufacturing to producethe kind of composite (having two elasticized regions) described inrespect to FIG. 5.

Central to the system 1001 is a conveyor assembly 1009 for receiving,manipulating, and conveying each of the non-woven web inputs. Theconveyor assembly 1009 is positioned and operatively associated with anelastic element applicator such as a spinning head assembly 1007, thatapplies elastic fibers or strands upon, onto, and/or integrally with thenon-woven web inputs. The spinning head assembly 1007 further includes aspinhead 1017, preferably in the form of a spinning bracket, or cylinder1017 and the like. The spin cylinder 1017 is configured to hold an “endsection” of the continuous strand WW (shown in FIG. 8) of elastic andmove it about a generally vertical plane XX in a reciprocal orrepetitive pattern (relative to the conveyor assembly 1009). This planeXX is defined by the area within the spinning perimeter of the cylinder1017 and which is traced by the outer most bracket or eye 1017 bsecuring the strand of elastic WW to the spin cylinder 1017. The pathsof the spinhead 1017 and the section of elastic strand retained therebyare provided on the plane XX.

As shown in the schematic of FIG. 6, non-woven inputs 1003 a and 1003 bare fed, utilizing a series of rollers, into the conveyor assembly 1009.Before the two non-woven webs are fed into the conveyor assembly 1009,the webs are directed through the folding guides or plates 1039. Thefolding guides 1039 serve to effectively reduce the overall width of thenon-woven web by folding the lateral or side edges along apre-determined, longitudinally-extending side fold line YY. The firstfolding guide 1039 a initiates the first 90° turn while the secondfolding guide 1039 b initiates a second 90° turn. The roller 1369disposed in between the guide 1039 a and 1039 b facilitates the foldingprocess. The two folding guides 1039 and roller 1369 may be referredtogether as a folding guide assembly.

The conveyor assembly 1009 is set up so as to guide these two non-wovenwebs 1003 a and 1003 b through the center of the assembly 1009 towardsand eventually inside the elastic spin cylinder 1017 (into the spinningpath). Once inside the spin cylinder 1017 the conveyor assembly 1009delivers the non-woven webs to each outside, upper and lower faces(outward faces) of the conveyor assembly 1009. At this point thedirection of travel of the non-woven webs is reversed and the webs aredirected out of the spin cylinder 1017. As the non-woven webs exit thespin cylinder 1017, an elastic strand WW is wrapped around the entireconveyor assembly 1009, and as it contacts the upper and lower face ofthe web platforms it comes into contact with the non-woven web. As shownin several of the Figures, the elastic strand WW is applied crosswise orlaterally on the web, and transverse to the direction of the moving web.The friction between the tensioned elastic strand and the non-woven webson the upper and lower faces of the conveyor assembly draws the“wrapped” elastic strand out of the spin cylinder 1017 and towardscontact with two further non-woven webs 1003 c and 1003 d.

The non-woven webs 1003 c and 1003 d are operatively positioned upstreamof an adhesive applicator 1013. Utilizing a system of rollers inconjunction therewith, the non-woven inputs 1003 c, 1003 d and adhesiveapplicators 1013 apply a web of pre-glued non-woven material onto theconveyor assembly 1009 and onto the elastic strand “wrapped” around thenon-woven webs 1003 a and 1003 b.

Furthermore, the system 1001 employs a standard elastic input source,e.g., a bobbin of elastic yarn, that feeds elastic strands or fibers WWonto a tensioning/speed controlling unit 1037 and then to the spincylinder or the spinning head 1017, so as to apply the strands WW ontothe conveyor assembly 1009 and the non-woven material webs conveyedtherethrough. Elastic is taken off the bobbin, box or positive drivesystem and fed through a tension and speed controlling motor towards thespin cylinder 1017. The elastic WW is delivered through a hollow shaftin the motor controlling the spin cylinder 1017. The elastic WW thenpasses into the spin cylinder 1017 and is guided by rollers, eyes or anyother suitable mechanism around the inside face of the spin cylinder1017.

FIGS. 7 and 8 provide alternate views of the spinning head assembly 1007and conveyor assembly 1009. As discussed above, the conveyor assembly1009 receives four separate webs of non-woven materials and outputs twowebs 1031 of elastic composite. FIGS. 9 and 10 are provided to furtherillustrate the process of making the elastic composite. These figures,more particularly FIG. 9, illustrate the paths taken by the non-wovenweb materials to and from the conveyor assembly 1009.

Referring to FIG. 9, reference letters A-G are used to refer to stagesin the process and in conjunction with the description of the process.As discussed above, non-woven raw material webs are fed into the processat stage A. These webs provide four separate non-woven web inputs intothe process. Non-woven webs 1 and 3 are combined to make an elasticcomposite output 1 (i.e., referred to in the Figures as the WRAPoutput). Non-wovens 2 and 4, which are both on the downside of thespinning head assembly 1007 and conveyor assembly 1009, combine to makea second elastic composite output 2 (i.e., WRAP 2).

At stage B, non-woven webs 1 and 2 are folded prior to being directed tothe conveyor assembly 1009. A predetermined width of non-woven is foldedover each side of the web to make two folded flaps VV. The width of theflap VV determines the width of the dead zone or non-elasticized regiondescribed previously, while the width of the non-woven, after folding,determines the width of the elasticized region. At stage C, thenon-woven webs 1 and 2 are fed into the conveyor assembly 1009, inparticular into the middle or inside of the conveyor assembly 1009 withthe folded side of each web facing the outside of or away from theconveyor assembly 1009. It should be noted that at this stage C,non-woven webs 1 and 2 are not bonded together. The conveyor 1009 thenfeeds the non-woven webs 1 and 2 towards the spinning head assembly1007. At stage D, the non-woven webs 1 and 2 have traveled almost thelength of the conveyor assembly 1009 and progresses into the spinningpath of spinning head assembly 1007 and intersecting the “spinning”vertical plane XX of the elastic strand WW. Further, at the end of theconveyor assembly 1009, the webs 1 and 2 are directed away from eachother and onto the outside of the conveyor 1009 and away from thespinning head 1007. Non-woven web 1 turns up on the upper side of theconveyor assembly 1009, while non-woven web 2 travels along the lowerside of the conveyor assembly 1009. At stage E, an elastic strand WW iswound around the folded non-woven webs 1 and 2, as these webs passthrough the spinning head and the vertical plane XX. The elastic strandWW is applied to the moving webs 1 and 2 cross-directionally to thedirection of the moving web. The movements of the webs 1 and 2 away fromwithin the spin cylinder 1017 draws the “wrapped” elastic strand out ofthe spin cylinder 1017.

Now turning to non-woven webs 3 and 4, these webs are provided to theconveyor assembly 1009 with adhesive applied on one side (i.e., appliedby the adhesive applicator 1013). At stage F, the non-woven webs 3 and 4are brought into contact with webs 1 and 2, respectively, and theelastic strands WW. As a result, the webs 1 and 3 sandwich elasticstrands WW on the upper side of the conveyor assembly 1009, andnon-woven webs 2 and 4 sandwich elastic strands WW on the under side ofthe conveyor assembly 1009. The elastic strands WW run between the twonon-woven elastic non-woven composite (cross-direction), but is then cutby a knife (see knife 1410 in FIG. 10, as described below), therebyseparating the two wrapped composites. At stage G, the composites 1 and2 are fed away from the conveyor assembly 1009 and the folded flaps onwebs 1 and 2 become unfolded, with guiding, to form a flat non-wovencomposite. Subsequently, the composites are guided from the spinninghead assembly 1007 and conveyor assembly 1009 and into furtherprocesses. As shown in FIG. 16, the elastic output webs arrive via asystem of rollers onto an elastic composite output reel 1005.

FIG. 10 provides an alternate view of the conveyor assembly 1009. ThisFigure further illustrates the movement of non-woven webs 1-4, and theapplication of elastic strands in a generally mutually parallel patternand generally spaced apart from one another. After cutting of theelastic with the knife 1410, two elastic composites are directed awayfrom the conveyor assembly 1009. It should also be noted that the systemadvantageously allows for improved control of the stretch of the elasticstrands.

As shown in FIGS. 8 and 10, the conveyor assembly 1009 preferablyincludes two web moving platforms 1412 which are juxtapositioned so asto provide an interface therebetween. Each web moving platform 1412includes a continuous belt 1414 supported about a plurality of rollers1416 so as to be capable of reciprocal motion. The two web movingplatforms 1412 are generally the same length and juxtapositioned so asto accommodate the non-woven webs 1 and 2 therealong from one end to theother end. Preferably, a roller 1416 is situated about midway betweenthe ends of the web moving platform so as to deliver the non-woven webs3 and 4 respectively to the web moving platform.

As shown in FIG. 6 and also FIG. 10, the spinning head assembly 1007 ispositioned about and in the vicinity of one end of the conveyor assembly1009. In operation, the spinning head 1017 spins about the verticalplane XX which intersects the ends of the web moving platforms 1412 soas to deliver the elastic strands WW around and about both web movingplatforms 1412. In operation, the first and second non-woven move alongthe outside or exposed surfaces or sides of the web moving platforms1412 and receives the elastic strands WW delivered by the spinning head1017. By way of its movement away from the spinning head 1017, themoving web draws the continuous elastic strand WW from the spinning head1017.

By pre-folding the two non-woven webs that are fed to the inside of theconveyor assembly 1009, it is possible to create an elastic compositewith cross directional stretch having non-elasticized regions (“deadzones”) along each edge. The width of the central elasticized region isfixed to the width of the conveyor platform 1412. The width of thenon-elasticized regions or dead zones is determined by the width of thefold VV. The fold VV in the non-woven is preserved by the conveyorassembly 1009 during application of the elastic element and is appliedin such a way that the folded edge of the non-woven is not in contactwith the elastic element WW. The fold VV is then allowed to open afterthe composite exits the conveyor assembly 1009 to provide a flat elasticcomposite with non-elasticized regions. By altering the alignment of thematerials as it enters the conveyor assembly 1009 or by changing thewidths of the materials used it is possible to create various compositedesigns.

FIGS. 6-10 and the above accompanying description illustrate a method ofmaking an elastic composite that is different from and precedes thepresent invention. Most of the steps, sub-processes, components andsub-systems can be employed, however, in the systems and methods of thepresent invention (which are described later in reference to FIGS.17-21). In fact, applicable detail descriptions of system components andoperation may be borrowed from this portion of the specification inexplaining the inventive systems, and methods later in this disclosure.Differences between the previously disclosed systems and the systems tobe described, in respect to the present invention, represent, or arisefrom, improvements provided by the present invention. Such differencesare discussed herein in more detail.

The above-described process provides an elastic composite with crossdirectional stretch properties and a single elasticized region. Theprocess also provides non-elasticized regions on either side of thecentral elasticized zone of the composite. The focus of the remainingdescriptions shifts now to an elastic composite having dual elasticizedregions.

Each of FIGS. 11A-11C illustrates an elastic composite 1110 containing apair of elasticized regions 1114. The elastic composite 1110 also hasthree non-elasticized zones or dead zones, including a central dead zone1150 extending longitudinally between the two elasticized regions 1114and side dead zones 1116 positioned on the other side of eachelasticized region 1150. The elastic composite 1110 may now be referredto herein as an elastic composite having dual elasticized regions. Suchan elastic composite may also be referred to as a dual elasticizedelastic composite.

In FIG. 11A, the elastic composite 1110 shown is formed from twodiscrete composite sections C1, C2. Each composite section C1, C2 ismanufactured independently as a discrete elastic composite having asingle elasticized region, employing, for example, the system describedabove in respect to FIGS. 6-10. Each elasticized region is “independent”of the other elasticized region in that each was applied and integratedwith a top and/or base layer in a construction different from that ofthe other elasticized regions. To form the dual-elasticized elasticcomposite, two of the singly elasticized composite sections C1, C2 arejoined together by overlapping one side edge of one composite sectionover a side edge of the other composite section. A suitable adhesive oradhesive means may be used to maintain bonding at the overlap. Theoverlap creates a multi-layer bonding portion B as shown in FIG. 11A,which also serves as a portion of the central dead zone.

The bonding portion B consists of a top non-woven layer 1118 and a baselayer 1120 of each composite section. Accordingly, the thickness of thebonding portion B and the central dead zone 1150 may be, at leastobservably, greater than the thickness of the rest of dual-elasticizedelastic composite. For each composite section C1, C2, the top non-wovenlayer 1118 and the base non-woven layer 1120 have the same width and theside edges are aligned. In further descriptions, reference to the sideedge of base layer may apply to the “side edge” of the elasticcomposite, and vice-versa.

Turning to FIG. 11B, a second dual-elasticized elastic composite 1110′is shown again consisting of two adjoined singly elasticized, compositesections C1′, C2′. For each composite section C1′, C2′, one of a toplayer 1118′ and a bottom layer 1120′ is wider than the other. Referringto the view of FIG. 11B, the right composite section C2′ has a bottomlayer 1120′ that extends farther laterally than the top layer 1118′,thereby forming a step. For the left composite section C1′, the toplayer 1118′ extends farther laterally than the bottom layer 1120′,thereby forming a ledge. By abutting the ledged side edge to the steppedside edge, a suitable construction joint is provided between the twocomposite sections C1′, C2′. An overlapping bonding portion B′ (andcentral dead zone 1150′) is also provided that consists of a single toplayer 1118′ and a single base layer 1120′ and is characterized by athickness generally consistent with the other portions of the dualelasticized elastic composite 1110′. A suitable adhesive or adhesivemeans may be employed to facilitate and maintain bonding between thelayers of the bonding portion.

FIG. 11C illustrates an improved dual elasticized elastic composite1110″. In addition to a pair of elasticized regions 1114″, the elasticcomposite also has two side dead zones 1116″ and a central dead zone1150″ situated between the elasticized regions 1114″. The thickness ofthe dead zone 1150″ is provided by a single top layer 1118″ and a singlebase layer 1120″ and is, therefore, consistent with the thickness ofother portions of the dual elasticized elastic composite 1110″. The dualelasticized elastic composite 1110″ provides a single compositestructure. The base layer 1120″ of the elastic composite 1110″ isprovided by a seamless sheet of non-woven (or other material). Theelastic composite 1110″ does not require joining of two discrete elasticcomposite sections. Rather, a web of the dual elasticized elasticcomposite 1110″ is generated linearly as output of the manufacturingprocess. As a seamless composite structure, the dual elasticizedcomposite 1110″ eliminates the bonding region required of the elasticcomposites in FIGS. 11A and 11B and thus, avoids the potential forleakage generally associated with these bonding regions B, B′. Theseamless composite structure is also more structurally sound than theother composites and has a higher tensile strength (laterally andlongitudinally).

As used herein, the term “seamless composite structure” shall refer to astructure that does not have a seam at which two or more originallyindependent sections are joined as one to form the present structure. Itshould be noted that the top layer 1118″ of the elastic composite 1110″in FIG. 11C may provide a single seam S″ along the central dead zone1150″ and thus, may not be referred to as “seamless.” This seam S″ ofthe top layers 1118″ is not, however, a seam of the elastic composite1110″ as that seam S″ does not extend through the thickness of the deadzone 1150″ and the multi-layer composite 1110″, and is not required tojoin two independent sections of the elastic composite 1110″.

As expected, the dual elasticized elastic composite 1110″ is generallyeasier to manufacture than the other composites in that it does notrequire the joining and bonding steps required described previously. Italso does not require the machines or manpower to implement these steps.Furthermore, the seamlessness of the elastic composite 1110″ isgenerally more aesthetically pleasing than the bonding regions B, B′. Byeliminating or reducing the use of adhesives, the central dead zone ofthe elastic composite 1110″ is also generally cleaner.

In each of the elastic composites 1110′ and 1110″ (FIGS. 11B and 11C),the top layer extends over and past the elastic elements to the sideedge or inwardly to the bonding seams S′ and S″. In each of the elasticcomposites 1110′ and 1110″ of FIGS. 11B and 11C, respectively, thecentral dead zone (1150′, 1150″) is composed of a top layer having aseam (S′, S″) and a base layer. Similarly, the side dead zones 1116′,1116″ are also constructed of at least two non-woven layers. To maintaina neat and uniform construction in these dead zones 1116′, 1116″, thetop layer and base layer are attached together using adhesives. As willbe further explained below, these adhesive areas are susceptible tofailure due to excessive or repeated loading, moisture, or deficientadhesive application. The application of adhesives can also be messy andunsightly.

For purposes of the present description, the term “non-woven” is used todescribe the principal material used in the construction of the materiallayers of the elastic composite. However, it should be noted that thisinvention is not limited to non-woven materials but may be applied toany material that is available in the form of a continuous sheet. Othermaterials suitable for this application include PE film, PEfilm/non-woven laminates and tissue.

FIG. 12 illustrates an improved elastic composite 1210 having dualelasticized regions 1214, according to the present invention. Theelastic composite 1210 may be characterized as having three primarycomponents: a base layer BW, a first elastic sub-composite SC1, and asecond elastic sub-composite SC2 spaced laterally from the first elasticsub-composite SC1. The first and second elastic sub-composites SC1, SC2correspond to the dual elasticized regions 1214 of the elastic composite1210. The base layer BW is preferably a non-woven material having afirst lateral side edge 1252 and a second lateral side edge 1254, which,in many applications, will provide a generally straight longitudinallyextending line. The side edge(s) 1252, 1254 of the base layer BW alsofunctions as the side edge(s) 1252, 1254 of the elastic composite 1210in the embodiments described herein. Moreover, the base layer BW and theelastic composite 1210 may be described as having a longitudinallyextending centerline AA that is consistent with a machine direction. Thedirection perpendicular to the centerline AA may be referred to as thelateral direction.

Each elastic sub-composite SC1, SC2, as further illustrated in theexploded view of FIG. 12A and the sectional views of FIGS. 12B and 12C,is preferably composed of a top non-woven layer I1, I2 and an elasticconstruction 1214 over which the top layer I1, I2 extends. Further, theelastic construction 1214 is provided by a plurality of elastic elementsEE that are mutually spaced apart and disposed in generally parallelrelation. As shown in FIG. 12, the elastic elements are independent fromone another, but within the same elastic construction, the elasticelements are preferably derived from the same continuous elastic strand.That is, the elastic elements have generally the same physicalproperties and are, in fact, severed sections of the same, previouslycontinuous elastic strand. Each elastic element is directed along alateral or cross-machine direction generally perpendicular to thelongitudinal centerline AA. The elastic construction 1214 may be furtherdescribed as providing a distribution of elastic elements that extend inthe longitudinal or machine direction (and preferably in parallel withthe longitudinal centerline). As further discussed herein, the elasticelements EE are preferably adhered to, first, the top layer by glue orequivalent, and secondly, in a similar fashion, to the base web.

As shown best in FIG. 12B, each elastic element EE extends laterally,but stops short of and is spaced apart from the side edge 1252, 1254. Inone aspect of the present invention, the top layer I1, I2 of thesub-composites SC1, SC2 extends over the elastic construction 1214, butonly slightly past the lateral extent of the elastic elements EE. Thus,as shown in FIGS. 12 and 12B, each elastic sub-composite SC1, SC2 isspaced laterally inward of the side edge 1252, 1254, to create a sidenon-elasticized region or dead zone 1216, 1218, the significance ofwhich has been previously described. In this embodiment, the side deadzones 1216 are of a single layer provided by the base web BW.

The two elastic sub-composites SC1, SC2 are also mutually spaced apartto define the central non-elasticized region or dead zone 1250. Asfurther illustrated in the cross-sectional view of FIG. 12B, the centralnon-elasticized region 1250, at least in this embodiment, consists of asingle layer of the base layer BW. Further, the central non-elasticizedregion 1250 is seamless and requires no joining or constructing ofmaterials, whether to join two halves of an elastic composite or adhereone layer to another layer. Accordingly, the elastic composite 1210 ofthe present invention is a seamless construction with a central deadzone 1250 that generally has a greater tensile strength than prior artconstructions. The design of the elastic composite 1210 also eliminatesany seams, which may be susceptible to failure and thus represent weakstructural points.

It also follows that the elastic composite, according to the presentinvention, requires less material than prior art elastic compositeshaving dual elasticized regions, which can translate to cost savings.Also, by eliminating the top layer in this region, the non-elasticizedregion can provide a more suitable and more reliable landing for a hookmaterial. Furthermore, the single layer, seamless non-elasticizedcentral region 1250 (and overall, the elastic composite) may be moreaesthetically pleasing.

The elastic composite 1210 may appear, or be used in, a finished product(e.g., a disposable absorbent garment) as a component having dualelasticized regions. That is, the elastic composite may be used in thedual elasticized form shown in FIG. 12. It is also possible, however,that the elastic composites 1210 may be provided only temporarily in thedual elasticized form. Such may be preferred for storage, packaging andshipping, and/or marketing purposes. The dual elasticized elasticcomposite may, in further applications, be split and thus, converted toa pair of separate, singly elasticized elastic composites.

FIGS. 13 and 13A depict an alternative embodiment of the elasticcomposite, according to the present invention. The alternative elasticcomposite 1310 is also provided with a base layer BW and dualelasticized regions 1314. The elasticized regions 1314 are laterallyspaced apart to create a central dead zone 1350. Furthermore, theelastic elements of the elasticized regions 1314 are spaced inwardly ofside edges 1352, 1354, thereby creating a pair of side dead zones 1316.

In this particular embodiment, a pair of elastic sub-composite SC1, SC2are positioned on the base web BW along the side edges 1352, 1354.Unlike the elastic sub-composites SC1, SC2 in FIG. 12, the elasticsub-composite SC1′, SC2′, in this embodiment, extend to the side edges1352, 1354. Thus, the dead zones 1316 of this elastic composite 1310 hasa pair of double layer, side dead zones 1316.

FIG. 14 illustrates a roll or web O1 of an elastic composite 1210 havingdual elasticized regions, according to the present invention. Such aroll or web represents the output of a process of manufacturing theelastic composite. In a suitable application, the elastic composite 1210is preferably cut along the longitudinal centerline AA to produce twoseparate elastic composites, for use as described previously and asdepicted in FIG. 1 for example (items 124 and 130). In the illustrationof FIG. 14, the web O1 of the elastic composite 1210 is provided on aspool 1420 and then, delivered to a knife mechanism 1440 or othercutting means, located downstream of the spool 1420. Downstream of theknife mechanism 1440, two strips or webs 1410 of single elasticizedelastic composites may be directed and/or fed to various stages of asystem of manufacturing a disposable absorbent garment.

Referring now to FIG. 14A, a roll or web of the elastic composite isalso shown being delivered from a spool 1420. In this illustration, twoparallel strips 1430 of a hook material are delivered and applied to themoving web O1 of the elastic composite 1210 downstream of the spool1420. The strips 1430 of hook material is preferably applied by glue oneither side of the longitudinal centerline AA. The resulting web is thenmoved through the mechanism 1440 and cut along the longitudinalcenterline AA. As a result, two webs 1410 of an elastic composite 1210having a single elasticized region may be delivered and/or fed tovarious stages of a manufacturing process, ultimately providing anelastic composite and a disposable absorbent garment, as an ear panel,waist band, and the like. In further applications, a single strip ofhook material may be applied to the web O1 and/or a shaped die cut maybe employed instead of the longitudinal cut.

FIG. 15 is a simplified illustration of an elastic composite strip 1510derived from the web of elastic composite O1, as shown in FIG. 14A. Theelastic composite 1510 represents one of the two elastic compositeshaving a single elasticized region 1514 that may be cut from thelongitudinally extending web 1410. The elastic composite 1510 has a baselayer BW and an elastic sub-composite SC1 of an elastic construction anda top non-woven layer 11. The sub-composite SC1 provides the singleelasticized region 1514. The elastic composite 1510 retains one-half ofthe previous central non-elasticized region 1550 (in contrast to the“full” central non-elasticized region in the web O1 of FIGS. 14 and14A). The elastic composite 1510 also retains a side non-elasticizedregion 1560 between the elasticized region 1514 and a side edge 1552.

As shown in FIG. 15, the central non-elasticized region 1550 is composedof a single layer of the base web material BW. A hook material 1580 (orother fastening mechanism) is directly planted on the base layer BW inthis non-elasticized region 1550, using adhesive means or the like.Loading on the hook material 1580 transfers directly to the base layerBW.

FIG. 15A illustrates a prior art elastic composite 1510′ with a singleelasticized region 1514′, a side non-elasticized region 1560′, and acentral non-elasticized region 1550′. The central non-elasticized region1550′ is provided by the base layer BW and the top layer I1′ whichextends laterally from the elasticized region 1514′. Unlike the elasticcomposite 1510 according to the present invention, a hook material 1580′(or other fastening mechanism) is glued directly to the top layer I1′ inthe central non-elasticized region 1550′. The top layer I1′ is furtherglued to the base layer BW′, also by known adhesive means 1590′. Thus,when the elastic composite 1510′ is manipulated or the hook material1580′ is loaded, the adhesive 1590′ between the top layer I1′ and thebase layer BW′ must resist. If the adhesive 1590′ is inadequate, the toplayer I1′ may be peeled off when the hook material 1580′ is beingpulled, for example. As one benefit of the elastic composite 1210 of thepresent invention, this potential weak spot is eliminated, therebyproviding an elastic composite construction having greater structuralintegrity. Furthermore, elimination of the excess top layer and adhesivein the landing zone of the hook material may provide some reduction inmaterial and construction costs. It may also result in a moreaesthetically pleasing surface. Among other things, it is easier toprevent wrinkles or undulations in the landing area with a single layermaterial construction.

The simplified flow chart 1600 of FIG. 16 illustrates a set of basicsteps or stages in a method of making an elastic composite having dualelasticized regions, according to the present invention. The simplifiedflowcharts of FIGS. 17 (1700) and 18 (1800) provide further exemplaryvariations of the inventive method. The simplified system illustrationsof FIGS. 19 and 20 each provide an exemplary system that may be employedto produce the inventive elastic composite. More specifically, thesystem of FIGS. 19 and 20 may be employed to generate a continuous webor roll O1 of an elastic composite 1210 having dual elasticized regions,according to the present invention.

Turning first to FIG. 16, the inventive method generally begins with theprovision of a web of a base material or base layer. As discussedpreviously, in these preferred embodiments, the base layer is providedby a non-woven material. Generally, in an initial step 16 a of theinventive method, a web of the base layer is conveyed, preferably towarda central integrating assembly of the manufacturing system. Then, anelasticized sub-composite is integrated with the base web (Step 16 b).As discussed in respect to the exemplary embodiments of FIGS. 12 and 13,the elastic sub-composite may be a construction consisting of a topnon-woven layer and a plurality of elastic elements that are spacedapart and disposed in generally parallel relation. Further, in asubsequent step 16 c, a second elastic sub-composite is integrated withthe base web, which preferably already has the first elasticsub-composite integrated. In this manner, an elastic composite havingdual elasticized regions is produced, according to the presentinvention.

FIGS. 17 and 18 illustrate further and exemplary variations of themethod described by the process of FIG. 16. Referring to the simplifiedflow chart 1700 of FIG. 17, in this embodiment, an initial step 17 a ofthe process requires the conveyance of a web of a top layer (e.g., anarrow web of non-woven material). Next, the elastic elements areapplied about or to the first web to produce a first elasticsub-composite (Step 17 b). A web of the base layer (base web) is alsoconveyed (Step 17 c) preferably toward a central integrating assembly.This first elastic sub-composite is then integrated with the base web(which is being conveyed) (Step 17 d). This generates a larger web orweb substrate having a single elasticized region thereon.

In this preferred embodiment, a second web of a top layer is conveyed(Step 17 e). Elastic elements are applied about or to this second web toproduce a second elastic sub-composite (Step 171). This second elasticsub-composite is then integrated with the base web to produce an elasticcomposite having dual elasticized regions (Step 17 g). Preferably, thesecond elastic sub-composite is applied such that the second elasticsub-composite is spaced apart from the first elastic sub-composite,thereby creating a central non-elasticized region therebetween. Thecentral non-elasticized region includes the imaginary longitudinalcenterline along which the elastic composite may be cut to produce twoseparate webs of elastic composites (having single elasticized regions).

FIG. 18 illustrates yet another exemplary variation of the inventivemethod of making the elastic composite in the form of a simplifiedprocess flow chart 1800, according to the invention. References to thesimplified flow chart 1800, and more particularly, the steps of themethod, are made in describing a system O1 of making an elasticcomposite (having dual elasticized regions) according to the invention.The system O1 is illustrated in FIGS. 19 and 20.

The system O1 according to the present invention includes two inputassemblies or reels 03 a and 03 b that each delivers a non-woven inputweb I1, I2. This exemplary system 01 further includes a third inputassembly or reel 03 c for delivering a web of a non-woven base layer(base web BW). Further yet, the system 01 employs an output assembly orreel 05 that receives or gathers a web (O1) of an elastic compositehaving dual elasticized regions, according to the present invention. Theoutput web O1 is equivalent to the webs O1 previously described inrespect to FIGS. 14 and 14A. These output webs O1 may further serve asinput to a system of manufacturing a disposable absorbent garment.

Central to the system 01 is a conveyor assembly C1 for receiving,manipulating, and conveying, among other things, each of the non-woveninput webs I1, I2. The conveyor assembly C1 includes a top conveyorplatform P1 and a bottom conveyor platform P2 for moving the input websI1, I2. The conveyor assembly C1 is positioned and operably associatedwith an elastic element applicator such as a spinning head assembly 07.The spinning head assembly 07 applies elastic fibers or strands upon,onto, and or integrally with the non-woven web inputs I1, I2. Thespinning head assembly 07 further includes a spinhead SH, preferably inthe form of a spinning bracket or cylinder SH. The spin cylinder SH isconfigured to hold an end section of the continuous strand ES of elasticand move the elastic strand ES about a generally vertical plane XX in areciprocal or repetitive pattern, as previously described. Generally,the system and method according to the invention employs a conveyorassembly C1, a spinhead SH, and other system components familiar tothose skilled in the relevant consumer product or manufacturing art, orother relevant art. Thus, details on the structure and operation ofthese system components are not included in the present description (butmay be easily accessed from present reference materials, including thetwo patent publications previously referenced herein).

In initial steps (18 a, 18 b) of the inventive method, the conveyorassembly C1 preferably conveys and guides the non-woven input webs I1,I2 between the platforms P1, P2 toward the spinhead SH and then, withinthe spinning path XX of the spinhead SH. Once inside the spinning pathXX, the conveyor assembly C1 delivers the non-woven web I1 to the upperface (outward faces) of the top conveyor platform P1 and non-woven webI2 to the lower face (outward face) of the bottom conveyor platform P2.At this stage, the directions of travel of the input webs I1, I2 arereversed and the webs I1, I2 are directed out of, and away from, thespinhead SH. As the input webs I1, I2 exit the spinhead SH, the elasticstrand ES is wrapped about both platforms, and as the strand ES contactsthe upper and lower face of the web platforms P1, P2, the strand EScomes into contact with the non-woven input webs I1,I2 moving thereon.

In this step 18 d of the inventive process, the elastic strand ES isapplied preferably cross-wise or laterally onto the webs I1, I2. Theelastic strand evolves into an elastic construction on the non-woven webI1, I2. The result is an elastic sub-composite SC1 or SC2 provided bythe engagement of a non-woven input web with the elastic elements of theelastic strand, as already disclosed in the prior art.

Referring also to FIG. 19, a third input reel 03 delivers a web ofnon-woven base layer or base web BW (Step 18 a). In this embodiment, asillustrated in FIGS. 19 and 20, this base web BW is directed toward thetop platform P1 of the conveyor assembly C1 via a series of rollers. Thebase web BW has a first side edge 52 and a second side edge 54. The pathof the base web BW also takes it through an adhesive applicator 13 thatapplies adhesive on the inside surface of the base web BW and along asection close to the first side edge 52. As shown in FIG. 20, the baseweb BW is purposely made wider than the narrower non-woven input websI1, I2. The path of the top elastic sub-composite SC1, converges withthe path of the base web BW on the top platform P1, and moreparticularly, along the first side edge 52 of the base web BW at whichadhesive is applied. The sub-composite SC1 and the base web BW mutuallyengage on the outside surface of the platform P1, thereby integratingthe sub-composite SC1 with the base web BW (Step 18 e). In thisembodiment, the resulting combination (SC1 and BW) is conveyed togethera short distance by the platform P1 and directed toward a knifemechanism KM. The knife mechanism KM severs the elastic strand toproduce discrete and independent elastic elements.

Accordingly, a web substrate WS is generated composed of a wide baselayer BW of non-woven and an elastic sub-composite SC1 positionedproximate the first side edge 52. The sub-composite SC1 provides anelastic construction of a plurality of spaced apart elastic elementsthat extend generally in the lateral direction and are disposed ingenerally parallel relation. In this embodiment, the input web or toplayer I1 extends only slightly past the lateral extent of the elasticelements. Further, the elastic sub-composite SC1 is spaced inwardly fromthe first side edge 52 to provide a single layer, non-elasticized regionbetween the sub-composite SC1 and the side edge 52.

Referring also to FIG. 20, the web substrate WS is directed away fromthe top platform P1 and directed through a series of turns thatultimately delivers the web substrate WS adjacent the bottom platformP2. It should be noted that FIG. 20 provides only a representativeillustration of a path that the web substrate WS may take to arrive atthe bottom platform P2. In this specific representation, the websubstrate WS is first directed upwardly away from the top platform P1and then makes a series of eight turns (T1 through T8) with the help ofrollers and tension guides (represented as T1-T8) (or equivalent). Alongthe way, the web substrate WS passes through a second adhesiveapplicator 13 (See FIG. 19). At this juncture, adhesive is appliedproximate the second side edge 54 of the base web BW away from the firstsub-composite SC1. With reference particularly to FIG. 20, after turnT8, the web substrate WS moves along the same direction as the reversedirection of the conveyor assembly C1 (away from the spinhead SH) butpositioned below the bottom conveyor platform P2. Furthermore, at thisstage and position, the web substrate WS is not directly aligned orcentered with the conveyor platforms P1, P2, but positioned laterallyaskew from the longitudinal centerline of the conveyor platforms P1, P2.As a result, the wider web substrate WS presents only a section near thesecond side edge 54 directly below the conveyor platform P2. Thissection or overlap can directly engage the platform P2.

As indicated in FIGS. 19 and 20, a second sub-composite SC2 is moved bythe bottom platform P2 into direct engagement with the approaching websubstrate WS. The second sub-composite SC2 is integrated with the websubstrate WS in the same manner as the first sub-composite SC1 (Step180. Thus, the second sub-composite SC2 is applied proximate the secondside edge 54 of the base web BW. The bottom platform P2 moves theresulting combination web O1 of non-woven layers and elasticconstruction away from the spinhead SH and toward the knife mechanismKM.

As a result, a new multi-component web O1 of elastic composite isgenerated. According to the present invention, the web O1 of an elasticcomposite includes a base web BW and dual elastic sub-composites SC1,SC2, and dual elasticized regions proximate the first and second sideedges 52, 54, respectively. The sub-composites SC1, SC2 are laterallyspaced apart to define a single layer, non-elasticized regiontherebetween. In this specific embodiment, the sub-composites SC1, SC2,and, more particularly, the elastic elements and top non-woven layersthat compose the sub-composites SC1, SC2, are also spaced inwardly fromthe first and second sides edges of the base layer, thereby defining asingle layer, a non-elasticized region along each side edge.

In a subsequent step 18 g of the inventive method, this web O1 ofelastic composite is directed by series of rollers to the output reel 05and gathered as a roll. The web or roll O1 on the output reel 05 may beremoved when full. The roll O1 may also be delivered directly to a knifemechanism KM, whereupon it is converted to two strips of singleelasticized composites. Furthermore, the output web O1 may be directedto a larger system for manufacturing disposable absorbent garments.

It should be noted that the directions and turns through which the websubstrate is directed, as discussed above, may be changed in alternativeembodiments. The specific paths illustrated in FIGS. 19 and 20 are, infact, representative and do not correspond exactly with any specificphysical arrangement. The path illustrated in FIGS. 19 and 20 areprovided only for exemplary purposes. Furthermore, in other embodiments,the base web BW and input reel 03 c may be provided near the bottomplatform P2, and thus, first directed toward the bottom platform P2rather than the top platform P1. In such an embodiment, the resultingweb substrate WS is directed through a series of turns that ultimatelypositions the web substrate WS adjacent the top platform P1, whereuponthe sub-composite SC1 is integrated with the web substrate WS.

In another embodiment, the system and method provides, in lieu of twonarrow input webs I1, I2, a single input web may be provided from asingle source or spool. This single non-woven input web has a width thatis generally twice the width of the narrow input webs 11, 12. This widerweb may then be split prior to delivery to the conveyor, so as toprovide the two narrow input webs (e.g., I1, I2) discussed above.

FIG. 21 provides yet another alternative system 101 of making an elasticcomposite having dual elasticized regions, according to the presentinvention. FIG. 21 also reveals an alternate method for making theinventive elastic composite. In this alternate system 101, the system101 may be characterized as having a first sub-system S1 and a secondsub-system S2 in series with the first sub-system S1. The firstsub-system S1 is to the left of the second sub-system S2 in theillustration of FIG. 21, and as will be revealed below S2, is downstreamof sub-system S1 in the exemplary process.

Each sub-system S1, S2 employs a conveyor assembly C1, C2, and aspinhead SH1, SH2. In contrast to the previously described system O1,this system 101 employs two input assemblies or reels for delivering abase web BW1, BW2. Furthermore, the system 101 requires two non-woveninput webs (I1, I2; I3, I4) for each of the sub-systems S1, S2. As aresult, the system and method according to this embodiment, generatestwo output webs O1, O2 of the elastic composite.

First, input webs I1 and I2 are delivered into conveyor C1. The spinheadSH1 applies a continuous elastic strand about the moving input webs I1,I2, thereby generating sub-composites SC1, SC2. In this embodiment, basewebs BW1 and BW2 are applied to the top and bottom platforms of theconveyor assembly C1, respectively, and engage the sub-composites SC1,SC2, respectively. Engagement of the base webs BW1, BW2 and thesub-composites SC1, SC2, delivers two separate web substrates WS1, WS2.In this embodiment, the movement of input webs I1, I2, the generation ofsub-composites SC1, SC2, and the delivery of web substrates WS1, WS2 arepreferably performed simultaneously. Thus, the output result of thefirst sub-system S1 are two separate web substrates WS1, WS2 composed ofa base web and an elastic sub-composite applied to one of two side edgesof the base web BW1, BW2.

As shown in FIG. 21, both web substrates WS1, WS2 are then directeddownstream into sub-system S2. In sub-system S2, non-woven input webs13, 14, are also moved into the conveyor assembly C2 and the spinheadSH2. Each of the input webs 13, 14 is generally of the same width as thenarrow input webs I1, I2 (in sub-system S1). As before, the spinhead SH2operates to apply elastic elements on the input webs 13, 14, therebygenerating a third and fourth elastic sub-composite SC3, SC4. Websubstrates WS1, WS2 which are outputs of sub-system S1, are thendirected to the top and bottom platforms, respectively, of the conveyorassembly C2. Before reaching the conveyor assembly C2, the section ofweb substrate WS1, WS2 adjacent the bare side edge (opposite of SC1,SC2) is passed through another adhesive applicator and provided withadhesive. This section adjacent the side edge then is brought intocontact with the sub-composite SC3, SC4 on the conveyor platforms. Thesub-composite SC3, SC4 merges along the second side edge of the websubstrate WS1 or WS2. As a result, a web O1, 02 of the elastic compositeis generated and delivered as output of the conveyor assembly C2. Thetwo webs O1, O2 of the elastic composites is then directed to an outputreel and gathered.

In further variations of the system of FIG. 21, multiple additionalsub-systems may be provided downstream of, and in series with,sub-systems S1, S2. In such embodiments, the widths of the base webs andinput webs may be varied to accommodate multiple elasticized regions ofan elastic composite. Further, in these embodiments, the conveyorassemblies and rollers are located to precisely position each incomingweb substrate for engagement with an additional sub-composite.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. It is to be noted that thedescription is not intended to limit the invention to the varioussystems, apparatus, and processes disclosed herein. Various aspects ofthe invention, as described above, may be applicable to other types ofdisposable absorbent articles, garments, and the like, and processes formaking the same. For example, the elastic composite described above, maybe incorporated in other disposable absorbent garments such as trainingpants, etc. or in other areas or as other components of the garment. Theelastic composite may also be incorporated into or with other garments,textiles, fabrics, and the like, or combinations thereof. Moreover, thevarious aspects of the process described in respect to FIGS. 19-21 maybe utilized to produce compositions, garments and articles other thanthose described herein. Such variations of the invention will becomeapparent to one skilled in the relevant consumer products art providedwith the present disclosure. Consequently, variations and modificationscommensurate with the above teachings, and the skill and knowledge ofthe relevant art, are within the scope of the present invention. Theembodiments described and illustrated herein are further intended toexplain the best modes for practicing the invention, and to enableothers skilled in the art to utilize the invention and other embodimentsand with various modifications required by the particular applicationsor uses of the present invention.

What is claimed is:
 1. An elastic composite for use in manufacturingdisposable absorbent garments, the elastic composite comprising: a baselayer having a pair of side edges and a longitudinal centerline spacedinwardly from the side edges; a first elastic construction adhered tothe base layer, the first elastic construction including a firstplurality of spaced apart elastic elements; a first top layer extendingover the first elastic construction; a second elastic constructionadhered to the base layer, the second elastic construction including asecond plurality of spaced apart elastic elements; and a second toplayer extending over the second elastic construction; wherein the firstand second top layers and the first and second elastic constructions arespaced apart to define a single-layer central non-elasticized regionbetween the first and second elastic constructions; and wherein at leastone of the first plurality of spaced apart elastic elements and at leastone of the second plurality of spaced apart elastic elements extendlaterally from the central non-elasticized region.
 2. The elasticcomposite of claim 1, wherein the first and second top layers are spacedapart to define a seamless non-elasticized region formed by the baselayer.
 3. The elastic composite of claim 1, wherein the first pluralityof elastic elements are spaced inwardly from the first side edge to forma first non-elasticized region therebetween, and the second plurality ofelastic elements are spaced inwardly from the second side edge to form asecond non-elasticized region therebetween.
 4. The elastic composite ofclaim 3, wherein the first and second top layers are spaced inwardlyfrom the first and second side edges, respectively, to definesingle-layer first and second non-elasticized regions.
 5. The elasticcomposite of claim 1, wherein the elastic elements in the first andsecond elastic constructions are disposed generally transverse to thelongitudinal centerline and in mutual generally parallel relation.
 6. Anelastic composite for use in manufacturing disposable absorbentgarments, the elastic composite comprising: a base layer; a firstelastic sub-composite adhered to the base layer, the first elasticsub-composite having a first plurality of spaced apart elastic elementsdisposed in generally parallel relation and a top layer extending overthe first plurality of elastic elements; and a second elasticsub-composite adhered to the base layer, the second elasticsub-composite having a second plurality of spaced apart elastic elementsdisposed in generally parallel relation and a top layer extending overthe second plurality of elastic elements; and wherein the first andsecond sub-composites are spaced apart to define a single-layer centralnon-elasticized region therebetween; and wherein the first plurality ofspaced apart elastic elements and the second plurality of spaced apartelastic elements extend laterally from the central non-elasticizedregion.
 7. The elastic composite of claim 6, wherein the first andsecond sub-composites are spaced apart to define a seamless centralnon-elasticized region formed by the base layer.
 8. The elasticcomposite of claim 7, wherein the base layer includes a first side edgeand a second side edge, the first plurality of elastic elements beingspaced inwardly from the first side edge to form a first non-elasticizedregion therebetween, and the second plurality of elastic elements beingspaced inwardly from the second side edge to form a secondnon-elasticized region therebetween.
 9. The elastic composite of claim8, wherein the first and second non-elasticized region consists of asingle material layer provided by the base layer.
 10. The elasticcomposite of claim 6, wherein the elastic elements extends generally inthe cross-machine direction.
 11. The elastic composite of claim 6,wherein each of the top layers extends laterally proximate the lateralextent of the elastic elements of the elastic sub-composites.